Winding cores with stratification motion

ABSTRACT

A winder and system for winding wire onto core supports of dynamo-electric cores with translational, rotational and radial motions with respect to a central longitudinal axis of the dynamo-electric core is provided. The radial motion may preferably be provided by an independent assembly. In one embodiment of the invention, the radial motion may be provided by rotating a cam disk which is movably connected to, and causes radial motion of, a pair of rollers. The pair of rollers are mounted on support arms which are connected to a needle for dispensing the wire such that movement of the pair causes similar movement of the needle. In another embodiment of the invention, an inclined way is coupled to a slide portion of the needle. When the inclined way is moved parallel to the axis, it causes a radial motion of the slide portion.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/350,925, filed Jan. 22, 2003, now U.S. Pat. No. 6,708,915, which is acontinuation of U.S. patent application Ser. No. 09/632,281, filed Aug.4, 200, now U.S. Pat. No. 6,533,208, which claims the benefit of thefollowing provisional applications: No. 60/148,473, filed Aug. 12, 1999;and No. 60/214,218, filed Jun. 23, 2000. All of these prior applicationare hereby incorporated by reference herein in their entireties.

BACKGROUND OF THE INVENTION

The present application relates to winding coils of wire onto poles ofdynamo-electric cores. More particularly, the coils are wound directlyinto the slots of cores by means of needles which dispense wires. Thewires are each drawn from tensioners.

During winding, relative motions occur between the needles and the corein order to deliver the wires and wind them around the poles. The shapesof the slots are defined by the contours of the poles. Such motions aresimilar to those described in commonly-assigned U.S. Pat. No. 5,413,289.The '289 patent, and any other patents mentioned herein, is herebyincorporated herein in its entirety.

It would be desirable to provide a winding apparatus capable ofrotational and translational movements with respect to the core whilestratifying the wire along the poles of the core.

SUMMARY OF THE INVENTION

Therefore, it is an object of the invention to provide a windingapparatus preferably capable of rotational, translational and radialmovements with respect to the poles of the core. This stratificationmovement can be considered to be a radial movement that moves thewinding needle along the radial extension of the poles. Thisstratification allows for pre-determined placement of the wire.Pre-determined placement of the wire preferably results in deeper anddenser winding of wire.

A winder for winding wires onto a coil support portion of adynamo-electric core is provided. The winder has a central longitudinalaxis and includes a plurality of needles, each needle for dispensing awire, a plurality of support members, each member supporting a singleone of the plurality of needles, a first assembly for producingtranslational movement of the members along the axis, a second assemblyfor producing relative rotational movement of the plurality of memberswith respect to the core, and a third assembly for producing radialmovement of each of the members perpendicular to the axis. The operationof the third assembly is substantially independent of the operation ofthe second assembly.

In another embodiment of the invention, the winder includes a singleneedle for dispensing the wire and a first assembly, the first assemblyincluding a winding shaft. The needle is preferably constrained to movetranslationally with the shaft. The first assembly is for producingtranslational movement of the shaft along the axis. The winder alsoincludes a second assembly for producing rotational movement of theneedle about the axis and a third assembly including a drive membermovably coupled to the winding shaft. Furthermore, relative rotationbetween the drive member and the winding shaft produces radial movementof the needle. In addition, the third assembly produces radial movementsubstantially independently of the rotational movement provided by thesecond assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects and advantages of the present invention willbe apparent upon consideration of the following detailed description,taken in conjunction with the accompanying drawings, in which likereference characters refer to like parts throughout, and in which:

FIG. 1 is an axial view of a core being wound according to theinvention.

FIG. 2 is a partial sectional view of an embodiment of a winderaccording to the invention.

FIG. 2 a is a full sectional view of an embodiment of a winder accordingto the invention.

FIG. 3 is another partial sectional view of an embodiment of a winderaccording to the invention.

FIG. 4 is a view from direction 4—4 of FIG. 3 of a portion of theembodiment shown in FIG. 3.

FIG. 5 is a view from direction 5—5 of FIG. 2 of a portion of theembodiment shown in FIG. 2.

FIG. 6 is a view from direction 6—6 of FIG. 2 of the embodiment shown inFIG. 2.

FIG. 7 is a view from direction 7—7 of FIG. 2 of a portion of theembodiment shown in FIG. 2.

FIG. 8 is another partial section view of an embodiment of a winderaccording to the invention.

FIG. 9 is an elevational view of an embodiment of a winder according tothe invention.

FIG. 10 is a partial sectional view taken from direction 10—10 of FIG. 9of the winder shown in FIG. 9.

FIG. 11 is a partial sectional view taken from direction 11—11 of FIG. 9of a portion of the winder and core according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

A typical core 10 wound according to the principles of the presentinvention is illustrated in FIG. 1. FIG. 1 illustrates an axial end 10′of core 10. Core 10 includes a pile of laminated portions, having anaxial configuration like 10′, stacked for a certain length into thepage. (Reference to the “page” as used herein indicates the plane of thedrawing page of the FIGS.). Such a length is often referred to as the“height of the core”.

The actual coils 102, 104 and 106 are wound around poles 108, by usingneedles 11, 12, and 13 which dispense wires 111, 112 and 113,respectively, onto specific poles, as illustrated in FIG. 1.

The wire turns 121, 122 and 123 of the coils become stratified alongpoles 108. This means that each wire turn tends to occupy an individuallayer along the poles. In FIG. 1 the turns are illustrated crossing theend faces, similar to end face 132, of the poles. The stratificationshown in FIG. 1 is such that the turns are preferably wound on layersprogressing inwardly towards the center of core 10—i.e., at longitudinalaxis 131. Each turn is also preferably wound around the pole sidessimilar to sides 134 and 136, and across opposite faces similar to face132.

To begin winding of the coils shown in FIG. 1, needles 11, 12, and 13are provided with translation strokes, parallel to sides 134 and 136,and into the page. During these strokes, the needle tips 142, 144 and146 are partially inserted in slots 152, 153 and 154 of core 10 to placethe wires along the respective pole sides. At the end of the translationstrokes, needle tips 142, 144 and 146 are located beyond the end facesof core 10.

At this point, needles 11, 12 and 13 can be rotated with respect tolongitudinal axis 131 of core 10, in order to place the wires across theend faces of the poles. It should be noted that, for the purpose of theembodiment described in FIGS. 1–8, the term rotational movementpreferably indicates that the core may be rotated around longitudinalaxis 131, while the needles remain stationary. At the end of therotations, needle tips 142, 144 and 146 may be aligned with adjacentslots, where they can start opposite translation strokes. Similarly tothe original translation strokes, needles 11, 12 and 13 accomplishopposite translation strokes with their tips partially inserted in theadjacent slots of the core in order to place the wires along the nearbypole sides. Following the opposite strokes, tips 142, 144 and 146 arelocated beyond the end faces of the core, and out of the page. Then, anopposite rotation can take place to align the tips with the slot wherethe motions started.

Such a combination of motions places single turns of coils, such ascoils 102, 104 and 106, completely around the poles. The combination ofmotions needs to be repeated for a number of times equal to the numberof turns. Furthermore, the combination of motions also must be repeatedfor the number of layers of turns that are wound around the poles. Thestratification of the turns shown in FIG. 1 can be implemented by movingthe needles along radiuses R1, R2 and R3 (respectively for needles 11,12 and 13) of core 10. The movements along the radiuses preferably occurincrementally along the radius length. The incremental movement can beimplemented at the start of each new turn.

Suitable criteria that can dictate when the needle should be moved alongthe radii, and how long the increments should be include the thicknessof the wire, the dimensions and winding requirements of the poles, etc.A correctly obtained stratification is of great importance forguaranteeing that the turns are tightly wound, and of the same length.Orderly stratification of the wires achieves more compact coils, whichultimately means that more turns can be wound in the same slot space,while preventing turns of adjacent poles from interfering with eachother.

The present invention provides a machine which achieves such astratification. Furthermore, the machine of the present invention isable to have multiple needles accomplish stratification, substantiallysimultaneously, along respective poles. This achievement is madepossible even for poles which are at a close angular distance from eachother around the center of core 10.

In addition, the machine is programmable so that the stratification canbe achieved in a variable and predetermined manner, depending on therequirements of the core and the coils which need to be wound.

As shown in FIG. 1, coils 102, 104 and 106 can be simultaneously woundby using respective and separate needles for each pole. The motions ofthe needles can also preferably be synchronized with respect to eachother. Winding multiple coils, by means of a plurality of needlesoperating substantially simultaneously, reduces the time required towind the totality of coils present in the core. As illustrated in FIG.1, the shape of the needles is preferably a “V” configuration at theneedle base because of the relatively small angular spacing madeavailable by the distance existing between the poles.

FIG. 2 is a partial section view as seen from direction 2—2 of FIG. 1,showing the apparatus of this invention for causing the needles to movewith translational, rotational and radial—i.e., stratification—motions.FIG. 2A shows a sectional view of the entire assembly 20. FIG. 3 is asection view similar to FIG. 2 and represents a continuation of FIG. 2(towards the left of the page containing FIG. 2). Furthermore, FIG. 3shows the completion of assembly 20. FIG. 4 is a view from direction 4—4of FIG. 3. Assembly 20 is partially visible in FIG. 2.

In FIG. 2, core 10 and the needles of FIG. 1 have been rotated to bringneedle 12 on axis 131. Three distinct assemblies 20 (shown in FIG. 3),21 (shown in FIG. 2 a) and 22 respectively generate the translationstrokes, relative rotation motions and the radial increments for windingof the turns. Each of the assemblies preferably provides for theindependent operation of each other assembly.

Assembly 20 comprises three tubes 11′, 12′ and 13′ carrying needles 11,12 and 13, respectively. FIG. 2 illustrates the connection of needle 12(in partial section view) to tube 12′, by means of bolt 12″ screwed intoan end cap of tube 12′. These tubes act as support members for theneedles. Tip 144 of needle 12, which is perpendicular to the length ofneedle 12, is clearly visible in FIG. 2. Needles 11 and 13 will beconnected in a similar manner to tubes 11′ and 13′. To avoidcomplicating FIG. 2, needles 11 and 13 (which are out of the plane ofFIG. 2) have been omitted from FIG. 2.

Wires 111, 112 and 113 are threaded through the respective needles toreach the core as shown in FIG. 1. Wires come from a respective supplyreel placed to the left of FIG. 3 and enter the tubes through nozzleslike 12′″, shown for tube 12′ in FIG. 3. To position the tips—e.g., tip144—with respect to core 10 as shown in FIG. 1, needles are providedwith bent portions—e.g., bent portion 222 shown in FIG. 2.

The following discussion relates to tube 12′ shown in FIGS. 2 and 3 butalso is extended to tubes 11′ and 13′, though they are not shown in FIG.3. Each of tubes 11′, 12′ and 13′ are connected to slide members 24, 25and 26, respectively. Slide members 24, 25 and 26 have narrow portionswhich are guided to move in radial directions R1, R2 and R3,respectively, by means of respective slots 24′, 25′ and 26′. These slotsare preferably machined in upstanding plate 27.

Upstanding plate 27 is preferably bolted to threaded sleeve 28 by meansof bolts (not shown).

Plate 27 is provided with dovetail recesses 27′ and 27″ that receivecorresponding guide male portions 31′ and 31″ of a bench portion ofcasing 31. This configuration allows plate 27 to translate in directionsT and T′, parallel to axis 131. (A portion of plate 27, as well as thebench portion of casing 31 has been omitted for the sake of clarity.)Sleeve 28 is threaded onto threaded bar 29, which, in turn, is supportedon bearing support 30 of casing 31 (see FIG. 3). End 29′ of threaded bar29 carries pulley 32 of belt transmission 32′, which leads to electricmotor 33. Electric motor 33 can be controlled to turn threaded bar 29for a predetermined number of revolutions. The result will betranslation of upstanding plate 27, and consequently of tubes 11′, 12′,and 13′ in directions T and T′ for pre-determined stroke lengths.

Assembly 22, for obtaining the stratification motion is illustrated inFIGS. 2, 5, 6 and 7. FIG. 5 is a partial section view from directions5—5 of FIG. 2. Tubes 11′, 12′ and 13′ are supported in preferablycylindrical guide sleeves 35, 36 and 37, respectively. Tubes 11′, 12′and 13′ are carried by bushes—e.g., bushes 38 and 39 of guide sleeve 35,which support tube 12′, as shown in FIG. 2. The bushes allow the tubesto translate in directions T and T′, within guide sleeves 35, 36 and 37,when upstanding plate 27 is moved backwards and forwards by electricmotor 33. Guide sleeves 35, 36 and 37 are parts of support arms 35′, 36′and 37′, respectively.

As shown in FIGS. 2, 5 and 6, support arms 35′, 36′ and 37′ arecontained in different, although parallel, planes with respect to theplane of the page in FIG. 5. Furthermore, 35′, 36′ and 37′ cross eachother as shown in FIG. 5. Support arms 35′, 36′ and 37′ can move alongradii R1, R2 and R3 to accomplish the radial motion required forstratification by being supported respectively on respective guidetracks 40, 41 and 42. Preferably, the radial movement of each of thesupport arms occurs substantially simultaneously. The guide tracksconsist of opposite portions—e.g., 41′ and 41″ of guide track41—extending along radii R1, R2 and R3. The guide tracks are assembledto an upright portion of casing 31. Their opposite portions—e.g., 41′and 41″ of guide track 41 (as also shown in FIG. 2)—are on respectivesides of aperture 31 a of casing 31. Aperture 31 a provides for passageof guide sleeves 35, 36 and 37. The size of the aperture shouldpreferably allow the movement of guide sleeves 35, 36 and 37 alongradiuses R1, R2 and R3 during the radial—e.g., stratification—motion.Guide tracks 40, 41, and 42 are also located on different, but parallelplanes with respect to each other and with respect to the page of FIG. 5(and as shown in FIG. 1), in order to conform to the planes containingsupport arms 35′, 36′ and 37′.

FIG. 6 is a view from direction 6—6 of FIG. 2 showing guide portions40′, 41′ and 42′ of guide tracks 40, 41 and 42 in perspective view,contained in their respective and different planes.

Support arms 35′, 36′ and 37′ include pairs of rollers 43, 44, and 45,respectively, for movably connecting to biting cam members 46, 47 and48, respectively.

FIG. 7 is a view from direction 7—7 of FIG. 2. Cam disk 49 is shown inFIGS. 2, 6 and 7.

As shown in FIG. 6, cam members 46, 47 and 48 have different andrespective extensions from cam disk 49 in order to reach pairs ofrollers pairs of rollers 43, 44, and 45.

Cam disk 49 is supported by shaft 49′ on bearing assembly 50 of casing31. Bearing assembly 50 allows cam disk 49 to rotate around axis 131.Cam disk 49 preferably is provided with a gear profile on its outercircumference, which meshes with pinion gear 52 of electric motor 53.Electric motor 53 is preferably supported by casing 31. In addition, camdisk 49 is provided with an aperture 749 to allow passage of guidesleeves 35, 36 and 37. Again, the size of aperture 749 should preferablyprovide for clearance with respect to movement of guide sleeves 35, 36and 37 along radiuses R1, R2 and R3 during the radial—i.e.,stratification—motion.

FIG. 8 shows a continuation towards the right of FIG. 2. FIG. 8 showscore 10, which is being wound. Core 10 can be supported in core casing60 of a vertical round table 61. FIG. 8 also illustrates assembly 21.Assembly 21 preferably accomplishes the relative rotation motions.

Core casing 60 preferably maintains core 10 centered on axis 131 ofcasing 31. This centers radii R1, R2 and R3 of core 10 on axis 131, asshown in the previous FIGS. Bearings 62 of round table 61 supports corecasing 60 for rotation around axis 131. In this way, core 10 can rotatearound axis 131 of casing 31 to provide the required relative rotationmotions between the needles and the core, as described in the foregoing.

The rotations are preferably imparted to core 10 casing by gear 63,which meshes with gear portion 60′ provided on the external surface ofcore casing 60. Gear 63 is supported and allowed to rotate byshaft/bearing assembly 64, assembled on round table 61. Assembly 64 islocated adjacent to core casing 60. Shaft 65 of shaft/bearing assembly64 is provided with a key portion 65′ which can be aligned (by rotationof round table 61) and connected to drive unit 66 of casing 31. Driveunit 66 preferably includes a shaft 67 driven by electric motor 68.Forward end 67′ of shaft 67 has a corresponding key portion capable ofconnecting itself to key portion 65′. This connection occurs by shiftingshaft 67 in direction Z, using air cylinder 75, which is connected tothe other end of shaft 67 by means of fork joint 69.

Shaft 67 is supported for rotation by means of support/bearing assembly70. This support/bearing assembly comprises bushes for supportingmovement of shaft 67 caused by air cylinder 75. The bushes are supportedin gear tube 72, which is supported for rotation by means of bearings73. Shaft 67 has key portions received in gear tube 72, for transmissionof relative rotations between gear tube 72 and shaft 67. Gear portion 74of gear tube 72 meshes with pinion 68′ of electric motor 68. Rotation ofelectric motor 68 rotates shaft 67 which, in turn, causes core 10 tohave the relative rotation motions with respect to needles 11, 12 and 13around axis 131. Motor 68 can also be used to index the core whenunwound poles need to be aligned with the needles.

Motors 33, 58 and 68 can be provided with position and speed feedbacksensors. Such a combination allows computer equipment (see computer 960in FIG. 9) to control the motors so that they achieve predetermined andprogrammable revolutions of rotation.

Thus, the needles may have relative motions of translation, rotation andstratification (described in the foregoing with reference to FIG. 1),occurring in required timing and synchronized between each other. A maincomputer (see computer 960 in FIG. 9) required to govern such aperformance can contain the relative programs and data. Position controlprinciples like those described in the '289 patent can be used to obtainaccurate predetermined trajectories of the needles with respect to thepoles. The same computer, or a different computer, can be provided withdifferent data when the amounts of the motions and the relative timingneed to be modified—e.g., when a different type of core needs to havewinding conditions set—i.e., requiring different translations, rotationsand radial.

It should be noted that the profile of the cam members govern thestratification motion of the needles, although the programmablerevolutions of motor 53 also influence the relative timing and speed ofthe needles. The cam members can be dismounted and substituted withothers when a different motion is required.

It should also be noted that round table 62 can have multiple corecasings carrying respective cores, each provided with a shaft/bearingassembly—e.g., shaft/bearing assembly 64. In this way, cores can be fedrapidly, and in sequence, to the needles in order to be wound. In such asituation, a core casing having a core which has already been wound canalign itself with another axis, where termination of the coil leads cantake place by means of equipment like the one described incommonly-assigned U.S. Pat. Nos. 5,065,503, 5,245,748, and 5,392,506. Itshould be noted that all patents mentioned herein are incorporated byreference in their entirety.

Another advantage of the embodiment described with relation to FIGS. 1–8is that the equipment for accomplishing the various relative motions ispreferably substantially independent—i.e., each assembly foraccomplishing a particular motion is substantially physically separatefrom each other assembly and each assembly is capable of providing theparticular motion for which it is responsible without causing the othermotions to occur. For example, substantially none of the equipment—e.g.,the motor—used to cause the radial motion moves with the equipment whichtranslates. Thus, the motor that provides the radial movement may besubstantially static—i.e., the motor preferably does not translate—whenthe translational motion occurs. This makes the translation equipmentlighter, which, in turn, provides higher translation speeds withoutcausing high levels of problematic vibrations. In addition, thestratification equipment has been conceived to move needles very closeto each other (as shown in FIG. 1), as is the constraint given by thesmall angular distance existing between the poles.

FIGS. 9–11 show another embodiment of the invention. This embodimentalso accomplishes the three movements described above by using a needleto dispense the wire. Needle 1045, (see FIGS. 10 and 11), is capable ofachieving translation movements (referenced by directions 913 and 914)to move along a side of the pole, rotational movement (referenced bydirections 915 and 916) to cross from one side to the other of the pole,and radial—i.e., stratification—movement (referenced by 917).

Needles and apparatuses for accomplishing the translation and rotationmovements have been described in commonly-assigned U.S. Pat. Nos.5,164,772 and 5,413,289. The following describes the implementation ofan apparatus that can also provide independent radial movement.

FIG. 9 is an elevational view of a winding machine according to theinvention capable of dispensing wires to form the coils of adynamo-electric component.

FIG. 10 is a partial cross-sectional view taken from direction 10—10 ofFIG. 9 of an apparatus for winding wire with the three motions—i.e.,translational, rotational and radial—discussed herein (the core has beenremoved from FIG. 10 for reasons of clarity).

Needle 1045 is preferably an extreme appendage of winding shaft 910.Winding shaft 910 is preferably provided with translation movement androtation movement such as the winding shaft described in the above-citedpatents—e.g., the '289 patent—or in another suitable fashion. Therotation movement may be implemented on the core to be wound, asdescribed above. The wire 950 required to wind the coils preferablypasses through winding shaft 910 to reach, and be dispensed by, needle1045 during winding.

With reference to FIG. 9, winding shaft 910 is driven to move withbackwards and forwards translation motions 913 and 914 andoppositely-directed rotation motions 915 and 916 in order to wind coilson dynamo-electric component 940 by an assembly mounted within casing942. Backwards and forwards translation motions 913 and 914 are parallelto axis 944. Rotation motions 915 and 916 may be performed about centeraxis 944. Dynamo electric component may also be centered on axis 944.

The radial motion, indicated by motion 917, may preferably beperpendicular to axis 944. The assembly within casing 942 may be totallymechanical with one input rotation motor or provided withindependently-controlled motors similar to the assembly described in the'289 patent. In any case, the translation and rotation motions areprovided preferably independently of the radial motion, as will bedescribed.

Winding shaft 910 protrudes from two opposite ends 946 and 948 of casing942. Wires 950 coming from supply drums and tensioners (not shown) enterthe winding shaft at end 952, while at the other end 954 of the windingshaft (shown in FIG. 10), needle 1045 is provided for moving withrespect to the poles in order to wind the coils.

FIG. 10 illustrates an assembly which has been introduced to cause theradial motion—i.e., stratification motion—in direction 917 of needle1045. The assembly is mostly contained within cylindrical protrusion 956of casing 942.

Winding shaft 910 extends to the left of FIG. 10 from bearing support1020 of casing 942. Bearing support 1020 supports the rotation andtranslation motions of winding shaft 910 caused by the assembly locatedto the left, within casing 942, and not shown in FIG. 10.

Gear wheel 1021 is preferably mounted on bearings 1022′ and 1022″ ofcasing 942. The center portion of gearwheel 921 is preferably hollow andprovided with key 1021′. Winding shaft 910 passes through the hollowcenter portion of gearwheel 1021. Gear wheel 1021 engages second gearwheel 1023 mounted on axle 1024. Axle 1024 is mounted on a supportbearing (not shown) of casing 942. Belt wheel 1025 is mounted on theopposite end of axle 1024. Belt wheel 1025 is driven by belt 1026, whichderives motion from the pinion wheel of motor 927 (shown in FIG. 9).Consequently, rotation of the pinion wheel of motor 27 causes gear wheel1021 to rotate on bearings 1022′ and 1022″. (It should be noted thatmotor 927 may be substantially static during translational movement ofwinding shaft 910.)

Rotation of gear wheel 1021 in a specific direction causes the radialmovement 917 of needle 1045, and thereby, to stratifies the wire duringwinding, as will become more apparent from the following. Drive tube1028, which serves as a drive member for the radial movements of needle1045 as will be explained, is preferably hollow so that it can beassembled coaxially on winding shaft 910 and so that it may containwinding shaft 910 and the wire. This assembly may be implemented wherewinding shaft 910 becomes smaller in its external diameter. Bearings1029 and 1030 are used to support drive tube 1028 on winding shaft 910,so that drive tube 1028 can rotate around winding shaft 910. However,drive tube 1028 is preferably fixed in directions 913 and 914 along thelength of winding shaft 910. Also, portion 1028′ of drive tube 1028preferably has a threaded portion for receiving recirculating balls.Registering cap 1041 has male threaded portion 1041′ which engages aninternal female threaded portion present in the end of winding shaft910. By tightening threaded portion 1041′, registering cap 1041 pusheson separation tube 1031, which is also mounted coaxially on windingshaft 910.

Consequently, separation tube 1031 restrains bearing 1030. In turn,bearing 1030 restrains drive tube 1028 and pushes it against bearing1029, which is shouldered by hollow shaft 1021. These restraining andpushing effects are parallel to the extension of winding shaft 910 alongcenter axis 944. In this way, drive tube 1028 is fixed along windingshaft 910 and, therefore, may translate together with winding shaft 910.Nevertheless, drive tube 1028 can be relatively moved—e.g., rotated—withrespect to, and preferably around, winding shaft 910, when required, byturning gear wheel 1023 with motor 1027. The configuration between drivetube 1028 and winding tube 910 may preferably be described as asleeve-thread configuration.

Bearings 1029 and 1030 are preferably implemented such that they act asaxial and radial supports for drive tube 1028 on winding shaft 910.Sleeve 1032 is provided with an internal threaded portion for receivingthe recirculating balls provided in portion 1028′ of drive tube 1028.Rotation of drive tube 1028 relative to winding shaft 910 preferablycauses sleeve 1032 to translate parallel to translation directions 913and 914 depending on the direction of rotation used to rotate drive tube1028. The recirculating balls preferably provide a low-friction runningsurface between drive tube 1028 and sleeve 1032 when the rotation andtranslation occur. Gear wheel 1021 preferably transmits the rotation todrive tube 1028. This rotation allows drive tube 1028 to rotate withrespect to winding shaft 910.

Key 1021′ of gear wheel 1021 is received in a portion of drive tube1028. This portion is preferably long enough to allow drive tube 1028 toaccomplish translation motions in directions 913 and 914 while stillaccommodating key 1021′.

First tube 1033 has end portion 1033′ assembled between axial bearings1034 and 1034′ so that first tube 1033 can be moved with sleeve 1032parallel to translation directions 913 and 914. Ring 1035 is threaded onsleeve 1032 and pushes on bearing 1034′ to maintain end portion 1033′between bearing 1034 and 1034′. Disk 1036 is preferably bolted to theopposite end of first tube 1033 by means of bolts 1036′. Disk 1036carries rods 1037 which extend preferably substantially parallel towinding shaft 910. The central portion of disk 1036 is preferably opento surround winding shaft 910, drive tube 928 and separation tube 1031.

The outside surface of second tube 1038 is preferably supported on theinside cylindrical surface of casing 942 to allow second tube 1038 toaccomplish the translational and rotational motions required by theneedles, referenced respectively with directions 913, 914 and 915, 916in FIG. 9. The outside surface of first tube 1033 is supported on theinside cylindrical surface of second tube 1038 to accomplish themovement of the first tube parallel to translation directions 913 and914.

Support tube 1039 is flanged to second tube 1038 by means of bolts1039′. In this way, support tube 39 is practically an axial extension ofsecond tube 1038. Consequently, support tube 1039 preferably providesthe translational and rotational motions required by the needle.Registering cap 1041 is also provided with referencing pins 1043 whichengage in recesses of the end face of winding shaft 910. This engagementof referencing pins 1043, and the joint existing between registering cap1041 and winding shaft 910, achieved by threaded portion 1041′,preferably rigidly connects registering cap 1041 to winding shaft 910.Registering cap 1041 is preferably bolted to second tube 1038 by meansof bolts 1042. This preferably rigidly connects second tube 1038 toregistering cap 1041 and finally to winding shaft 910. As a result ofthis connection, winding shaft 910 drives second tube 1038 to accomplishthe translational and rotational motions required by the needle orneedles.

Consequently, support tube 1039 also accomplish the translational androtational motions required by the needle or needles.

End member 1046 is bolted to rods 1037 by means of bolts like 1044(shown in a cut out of member 1046). Portion 1046′ of end member 1039 isan inclined way 1046′ for receiving slide portion 1045′ of needle 1045.The inclined way preferably has an inclination which converges towardsaxis 944 in direction 914. The section of the inclined way can have a Tform. Consequently slide portion 1045′ of needle 1045 should preferablyhave a corresponding T form. Needle 1045 is preferably hollow forpassage of wire 950. Member 1046 is provided with passage 1046″ formaking wire 950 reach needle 1045. Needle 1045 is supported duringstratification movement 917 by the sides of radial bore 1045″ present insupport tube 1039.

Translation of sleeve 1032, preferably by rotation of motor 927, causesend member 1046 to be translated parallel to directions 913 and 914because of the connection obtained between first tube 1033 and rods1037. When end member 1046 translates in direction 914, inclined way1046′ runs on slide portion 1045′ of needle 1045. By having inclined way1046′ run on slide portion 1045′, stratification movement 917 of needle1045 is preferably caused. By translating end member 1046 oppositely (indirection 913), needle 1045 preferably accomplishes an opposite movementwith respect to 917 in order to bring needle 1045 in a stratificationmotion towards an innermost position of the stratification movement.Movement of needle 1045 in a direction opposite to direction 917, andtherefore, stratification in this opposite direction, may also beaccomplished according to the invention.

Motor 1027 is preferably connected to a computer 960 (see FIG. 9) andappropriate drive that may cause the needle to accomplish thestratification motion in a predetermined time relation or positionrelation with respect to the translation movements and rotationmovements accomplished by winding shaft 910.

For example, a certain increment of stratification motion 917 can beaccomplished every time winding shaft 910 has completed a sequence ofbackwards and forwards translational movements and two oppositerotations—i.e., following each completed cycle. This preferablycorresponds to the needles having moved once around a respective coilsupport (or pole) that they are winding in order to form a turn. Anincrement of the stratification movement after such a sequence willshift the successive turn preferably along the coil's support. Timing orreaching of predetermined positions by the needle or needles, during thetranslation and rotation motions can be used to implement preferablyincremental stratification movement in direction 917 or in a directionopposite to direction 917.

In FIG. 10, for reason of clarity only one needle 1045 has been shown.However, end member 1046 can have a plurality of inclined ways like1046′. Each of the ways may be utilized for a respective needle likeneedle 1045. The inclined ways and the needle should preferably bepositioned around axis 944 to be aligned with respective coil supportsthat may require winding.

In conclusion, winding shaft 910 is able to make the needles accomplishthe required translational and rotational motions referenced withdirections 913, 914 and 915, 916. At preferably substantially the sametime, an assembly has been introduced around, and partially carried by,winding shaft 910 for causing the needles to accomplish stratificationmotion 917 when required. The assembly preferably produces an axialmovement of sleeve 1032 which becomes converted into the stratificationmotion required by the needles. Furthermore, the axial movement isindependently-driven—i.e., by motor 1027 or other suitable device, suchas a compressed-air source—with respect to the translational androtational movements of the needles referenced with directions 913, 914and 915, 917.

FIG. 11 is a partial view from direction 11—11 of FIG. 9 showing needle1045 in relation to a pole or coil support 1109′ of dynamo electriccomponent 1109 and after a certain number of turns have been wound withwire 950. Stratification motion 917 preferably distributes the turnsalong coil support 1109′ as shown. Without such a stratification motion,the turns may be distributed unevenly and sub-optimally.

Thus, an apparatus for dispensing wire from a needle having atranslational, rotational, and radial component is provided. Personsskilled in the art will appreciate that the principles of the presentinvention can be practiced by other than the described embodiments,which are presented for purposes of illustration and not of limitation,and the present invention is limited only by the claims which follow.

1. A winder for winding wires onto a coil support portion of a dynamo-electric core, the winder having a central longitudinal axis, the winder comprising: a plurality of needles, each for dispensing a wire; a plurality of support members, each member supporting a single one of the plurality of needles; a first assembly for producing translational movement of the members along the axis; a second assembly for producing relative rotational movement of the plurality of members with respect to the core; and a third assembly for producing radial movement of each of the members perpendicular to the axis, and wherein the operation of the third assembly is independent of the operation of the first assembly.
 2. The winder of claim 1, wherein the operation of the first assembly is independent of the operation of the second assembly.
 3. The winder of claim 2, wherein the operation of the third assembly is independent of the operation of the second assembly.
 4. The winder of claim 1, wherein the third assembly comprises a motor for producing the radial movement.
 5. The winder of claim 4, wherein the motor is substantially static during the translational movement.
 6. The winder of claim 1 further comprising a plate that fixedly supports the plurality of members.
 7. The winder of claim 6, wherein each of the plurality of support members comprises a support tube, and wherein the first assembly provides translational movement to the plate.
 8. The winder of claim 6, wherein each of the plurality of support members comprises a support tube, and wherein the plate comprises an aperture to allow the radial movement of the tubes.
 9. The winder of claim 1, wherein at least one of the first, second, and third assemblies is provided with at least one feedback sensor.
 10. The winder of claim 9, wherein at least one of the translational, rotational, and radial movements of the plurality of support members is programmable by a computer coupled to the at least one feedback sensor.
 11. The winder of claim 1, wherein the third assembly produces incremental radial movement of each of the plurality of support members.
 12. The winder of claim 1, wherein the third assembly produces bi-directional radial movement of each of the plurality of support members perpendicular to the axis.
 13. The winder of claim 1, wherein each of the plurality of support members comprises a support tube, and wherein the third assembly produces radial movement of each of the tubes substantially simultaneously.
 14. The winder of claim 1 further comprising a plurality of support arms, wherein each of the plurality of support arms fixedly supports the support members and each of the plurality of support arms defines a different plane, each of said planes being parallel to one another and perpendicular to the axis.
 15. A winder for winding a wire onto a coil support portion of a dynamo-electric core, the winder having a central longitudinal axis, the winder comprising: a needle for dispensing the wire; a first assembly, the first assembly comprising a winding shaft, the needle being constrained to move translationally with the shaft, the first assembly being for producing translational movement of the shaft along the axis; a second assembly for producing rotational movement of the needle about the axis; and a third assembly comprising a drive member movably coupled to the winding shaft, wherein relative rotation between the drive member and the winding shaft produces radial movement of the needle, and wherein the operation of the third assembly is independent of the operation of the first assembly.
 16. The winder of claim 15 further comprising a plurality of needles.
 17. The winder of claim 16, wherein the third assembly produces radial movement of each of the plurality of needles substantially simultaneously.
 18. The winder of claim 15, wherein the operation of the first assembly is independent of the operation of the second assembly.
 19. The winder of claim 18, wherein the operation of the third assembly is independent of the operation of the second assembly.
 20. The winder of claim 15, wherein the third assembly comprises a motor for producing the radial movement.
 21. The winder of claim 20, wherein the motor is substantially static during the translational movement.
 22. The winder of claim 15, wherein the drive member comprises a drive tube.
 23. The winder of claim 15, wherein at least one of the first, second, and third assemblies is provided with at least one feedback sensor.
 24. The winder of claim 23, wherein at least one of the translational, rotational, and radial movements of the plurality of support members is programmable by a computer coupled to the at least one feedback sensor.
 25. The winder of claim 15, wherein the third assembly produces incremental radial movement of the needle.
 26. The winder of claim 15, wherein the third assembly produces bi-directional radial movement of the needle.
 27. The winder of claim 15, wherein the drive member is coupled in a sleeve-thread configuration with the winding shaft.
 28. The winder of claim 15, wherein the drive member is coaxial with the winding shaft.
 29. The winder of claim 15, wherein the drive member substantially surrounds the winding shaft.
 30. A method for simultaneously winding a plurality of wires on a dynamo-electric core having a central longitudinal axis, the method comprising: winding each of the wires along a respective coil support in a first direction, the first direction being parallel to the axis; winding each of the wires across a respective face of the respective coil support in a first rotational direction about the axis; winding each of the wires in a second direction along the respective coil support, the second direction being opposite the first direction; winding each of the wires across a respective second face of the respective coil support in a second rotational direction about the axis, the second rotational direction being opposite the first rotational direction; and independently stratifying each of the wires in a radial direction perpendicular to the axis along the coil support.
 31. The method of claim 30, wherein the stratifying of each of the wires in a radial direction comprises incrementally stratifying each of the wires in the radial direction.
 32. The method of claim 30 further comprising programming the location and duration of each of the winding and the stratifying using a computer.
 33. The method of claim 30, wherein the stratifying of each of the wires in a radial direction comprises using a motor, and wherein the winding of each of the wires in the first direction and the winding of each of the wires in the second direction occur without moving the motor.
 34. The method of claim 30, wherein the independently stratifying each of the wires comprises stratifying each of the wires independently of the winding of each of the wires in the first direction and independently of the winding of each of wires in the second direction.
 35. The method of claim 30, wherein the independently stratifying each of the wires comprises stratifying each of the wires independently of the winding of each of the wires in the first rotational direction and independently of the winding of each of the wires in the second rotational direction.
 36. The method of claim 30, wherein the winding of each of the wires in the first direction and the winding of each of the wires in the second direction comprises winding each of the wires in the first direction and winding each of the wires in the second direction independently of the winding of each of the wires in the first rotational direction and independently of the winding of each of the wires in the second rotational direction. 